Iwasa Technology Co.

Kōtō-ku, Japan

Iwasa Technology Co.

Kōtō-ku, Japan
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Tsuji I.,Iwasa Technology Co. | Kawasaki K.,Niigata University | Gunbara H.,National Institute of Technology, Matsue College
American Gear Manufacturers Association Fall Technical Meeting 2012, AGMA | Year: 2012

In this paper, a manufacturing method of the pinion member of large-sized skew bevel gears using a multi-axis control and multi-tasking machine tool respecting an existing gear member is proposed. First, the tooth surface forms of skew bevel gears are modeled. Next, the real tooth surfaces of the gear member are measured using a coordinate measuring machine and the deviations between the real and theoretical tooth surface forms are formalized using polynomial equations. It is possible to analyze the tooth contact pattern of the skew bevel gears with respect to the deviations of the real and theoretical tooth surface forms by expressing the deviations as polynomial equations. Further, the deviations of the tooth surface form of the gear member are reflected in the analysis of the tooth contact pattern and transmission errors, and the tooth surface form of the pinion member that has good performance mating with the existing gear member is determined. Finally, the pinion member is manufactured by swarf cutting using a multi-axis control and multi-tasking machine tool. Afterward, the real tooth surfaces of the manufactured pinion member are measured using a coordinate measuring machine and the tooth surface form errors are detected. In addition, the tooth contact pattern of the manufactured pinion member and existing gear member is compared with those of tooth contact analysis. The results show that there is good agreement.


Tsuji I.,Iwasa Technology Co. | Kawasaki K.,Niigata University | Gunbara H.,National Institute of Technology, Matsue College | Houjoh H.,Tokyo Institute of Technology | Matsumura S.,Tokyo Institute of Technology
Journal of Mechanical Design, Transactions of the ASME | Year: 2013

Straight bevel gears are widely used in the plant of large-sized power generation when the gears have large size. The purpose of this study is to manufacture the large-sized straight bevel gears with equi-depth teeth on a multitasking machine. The manufacturing method has the advantages of arbitrary modification of the tooth surface and machining of the part without the tooth surface. For this study, first, the mathematical model of straight bevel gears by complementary crown gears considering manufacture on multitasking machine is proposed, and the tooth contact pattern and transmission errors of these straight bevel gears with modified tooth surfaces are analyzed in order to clarify the meshing and contact of these gears. Next, the numerical coordinates on the tooth surfaces of the bevel gears are calculated and the tooth profiles are modeled using a 3D-Computer-Aided Design (CAD) system. Five-axis control machines were utilized. The gear-work was machined by a swarf cutting using a coated carbide end mill. After rough cutting, the gear-work was heat-treated, and it was finished based on a Computer-Aided Manufacturing (CAM) process through the calculated numerical coordinates. The pinion was also machined similarly. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detected using the measured coordinates. As a result, the obtained tooth flank form errors were small. In addition, the tooth contact pattern of the manufactured large-sized straight bevel gears was compared with those of tooth contact analysis. The data showed good agreement. © 2013 American Society of Mechanical Engineers.


Tsuji I.,IWASA Technology Co. | Gunbara H.,National Institute of Technology, Matsue College | Kawasaki K.,Niigata University | Takami A.,National Institute of Technology, Matsue College
Proceedings of the ASME Design Engineering Technical Conference | Year: 2011

The purpose of this research is to develop a high-performance face gear set for aircraft. The geometrical design method of the face gear has already been proposed, and how to decide an effective engagement area under the design parameter has been clarified. A numerical example is presented based on the proposed method. Before machining test, the modified-tooth was decided by the developed Tooth Contact Analysis (TCA) program in order to control the tooth contact pattern. The influence of alignment error of each axis of gear was investigated using TCA. The designed modified-tooth was processed by the Multi-Tasking machine. Finally, running test was performed at a pinion rotating speed of 970 rpm. The face gear set can be operated continuously at an maximum load torque 1390 N • m, without any trouble. The transmission efficiency reached 98.9% under maximum load torque. This cutting method of the face gear introduces a new degree of freedom for defining optional shapes of tooth modification. Copyright © 2011 by ASME.


Kawasaki K.,Niigata University | Tsuji I.,Iwasa Technology Co. | Gunbara H.,National Institute of Technology, Matsue College
Proceedings of the ASME Design Engineering Technical Conference | Year: 2011

Straight bevel gears are widely used in the plant of large-sized power generation when the gears have large size. The purpose of this study is to manufacture the large-sized straight bevel gears with equi-depth on multi-tasking machine. The manufacturing method has the advantages of arbitrary modification of the tooth surface and machining of the part without the tooth surface. For this study, first the mathematical model of straight bevel gears by complementary crown gears considering manufacture on multi-tasking machine is proposed, and the tooth contact pattern and transmission errors of these straight bevel gears with modified tooth surfaces are analyzed in order to clarify the meshing and contact of these gears. Next, the numerical coordinates on the tooth surfaces of the bevel gears are calculated and the tooth profiles are modeled using a 3D-CAD system. 5-axis control machines were utilized. The gear-work was machining by a swarf cutting using a coated carbide end mill. After rough cutting, the gear-work was heat-treated, and it was finished based on a CAM process through the calculated numerical coordinates. The pinion was also machined similarly. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detected using the measured coordinates. As a result, the obtained tooth flank form errors were small. In addition, the tooth contact pattern of the manufactured large-sized straight bevel gears was compared with those of tooth contact analysis. As a result, there was good agreement. Copyright © 2011 by ASME.


Kawasaki K.,Niigata University | Tsuji I.,Iwasa Technology Co. | Gunbara H.,National Institute of Technology, Matsue College | Houjoh H.,Tokyo Institute of Technology
Mechanism and Machine Theory | Year: 2015

Abstract A method for remanufacturing pinion member of large-sized skew bevel gears using a CNC machining center and respecting an existing gear member is proposed. For this study, first the tooth surface forms of skew bevel gears are modeled mathematically. Next, the real tooth surfaces of the existing gear member are measured using a coordinate measuring machine and the deviations between the real and theoretical tooth surface forms are formalized using polynomial expression. Moreover, the tooth contact pattern and transmission errors reflecting the deviations of the tooth surface forms of the gear member are analyzed, and the tooth surface form of the pinion member that has good performance mating with the existing gear member is designed. The pinion member was remanufactured by swarf cutting using a CNC machining center. The gear member is also remanufactured using this method in order to apply to the case where pinion member exists in reverse or both gear and pinion members do not exist. The tooth surface form deviations were detected, and the experimental tooth contact pattern of the pinion and gear members was compared with analytical one. The results showed good agreement. © 2015 The authors.


Kawasaki K.,Niigata University | Tsuji I.,Iwasa Technology Co. | Gunbara H.,National Institute of Technology, Matsue College
Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science | Year: 2015

Double-helical gears are usually manufactured using special type of machine tools, such as gear hobbing and shaping machines. In this paper, a manufacturing method of double-helical gears using a CNC machining center instead of the special type of machine tools is proposed. This manufacturing method has the following advantages: (i) the tooth surfaces can be modified arbitrarily, (ii) all we have to do in gear machining is only one machine setting, (iii) the hole and blank diameter and so on except the tooth surface can be also machined, and (iv) the auxiliary apparatus, special type of tools, and special type of machine tools are not needed. For this study, first the tooth profiles of the double-helical gear were modelled using a 3D computer-aided design system and the gear was machined using a CNC machining center based on a computer-aided manufacturing system. Next, the profile deviations, helix deviations, pitch deviations, and surface roughnesses of the manufactured double-helical gears were measured. Afterwards, the relationship between the tool wear and life time of the end mill were made clear. Finally, this manufacturing method was applied to the gears for a double-helical gear pump. As a result, the validity and effectiveness of the manufacturing method of double-helical gears using a CNC machining center were confirmed. © 2015 Institution of Mechanical Engineers.


Kawasaki K.,Niigata University | Tsuji I.,Iwasa Technology Co.
Proceedings of the ASME International Design Engineering Technical Conferences and Computers and Information in Engineering Conference 2009, DETC2009 | Year: 2010

The demand of large-sized spiral bevel gears has increased in recent years and hereafter the demand may increase more and more. The large-sized spiral bevel gears with equi-depth teeth are usually manufactured based on Klingelnberg cyclo-palloid system. In this paper, the tooth contact pattern of large-sized spiral bevel gears in this system are investigated analytically and experimentally. First, the tooth contact pattern and transmission errors of such gears are analyzed. The analysis method is based on simultaneous generations of tooth surface and simulations of meshing and contact. Next, the large-sized spiral bevel gears are manufactured and the tooth contact pattern of these gears is investigated experimentally. Moreover, the real tooth surfaces are measured using a coordinate measuring machine and the tooth flank form errors are detected using the measured coordinates. It is possible to analyze the tooth contact patterns of the spiral bevel gears with consideration of the tooth flank form errors expressing the errors as polynomial equations. Finally, the influence of alignment errors due to assembly on the tooth contact pattern is also investigated analytically and experimentally. These analyzed results were compared with experimental ones. As a result, two results showed a good agreement. Copyright © 2009 ASME.


Tsuji I.,IWASA Technology CO.
Nihon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C | Year: 2011

The purpose of this research is to develop a high-performance face gear set for aircraft. The geometrical design method of the face gear has already been proposed, and how to decide an effective engagement area under the design parameter has been clarified. A numerical example is presented based on the proposed method. The designed modified-tooth was processed by the Multi-Tasking machine. Finally, running test was performed at a pinion rotating speed of 970 rpm. The face gear set can be operated continuously at an maximum load torque 1390 N m, without any trouble. The transmission efficiency reached 98.9% under maximum load torque. © 2011 The Japan Society of Mechanical Engineers.


Kawasaki K.,Niigata University | Tsuji I.,Iwasa Technology Co.
Applied Mechanics and Materials | Year: 2014

Large-sized spiral bevel gears are usually manufactured based on a cyclo-palloid system and have equi-depth teeth as well as a face hobbing system by a continuous cutting procedure using a special generator. It has been possible to machine the complicated shape because of the development of a multi-axis control and multi-tasking machine tool.The manufacturing method of the gears has been proposed using this development process. In this method, the spiral bevel gears are modeled based on a CAD system and are machined based on a CAM system. In this paper, the cutting performance in machining of the large-sized spiral bevel gears using the multi-axis control and multi-tasking machine toolis investigated. As a result, the relationship between the tool life of end mill and gear accuracy were made clear. The surface roughness and tool mark of the machined gears were compared with those using the special generator. © (2014) Trans Tech Publications, Switzerland.

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